CA2488528A1 - Deck board with composite base and pvc cover - Google Patents
Deck board with composite base and pvc cover Download PDFInfo
- Publication number
- CA2488528A1 CA2488528A1 CA002488528A CA2488528A CA2488528A1 CA 2488528 A1 CA2488528 A1 CA 2488528A1 CA 002488528 A CA002488528 A CA 002488528A CA 2488528 A CA2488528 A CA 2488528A CA 2488528 A1 CA2488528 A1 CA 2488528A1
- Authority
- CA
- Canada
- Prior art keywords
- main
- plank
- deck
- plank member
- main plank
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 13
- 238000010276 construction Methods 0.000 claims abstract description 28
- 239000011230 binding agent Substances 0.000 claims abstract description 4
- 239000003000 extruded plastic Substances 0.000 claims abstract 2
- 125000006850 spacer group Chemical group 0.000 claims description 6
- 238000002347 injection Methods 0.000 claims description 4
- 239000007924 injection Substances 0.000 claims description 4
- 239000007787 solid Substances 0.000 claims description 4
- 239000003086 colorant Substances 0.000 claims description 2
- 230000003014 reinforcing effect Effects 0.000 claims description 2
- 239000000463 material Substances 0.000 description 16
- 230000008901 benefit Effects 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 238000001746 injection moulding Methods 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
- E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
- E04B5/12—Load-carrying floor structures formed substantially of prefabricated units with wooden beams
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
- B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING
- B63B5/00—Hulls characterised by their construction of non-metallic material
- B63B5/02—Hulls characterised by their construction of non-metallic material made predominantly of wood
- B63B5/06—Decks; Shells
- B63B5/10—Decks; Shells with multiple-layer planking
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/02005—Construction of joints, e.g. dividing strips
- E04F15/02022—Construction of joints, e.g. dividing strips with means for aligning the outer surfaces of the flooring elements
Abstract
A deck plank comprises a main plank member and a top cap which removably secures to the main plank member.
The main plank member has a construction of composite materials including a binder used to hold the composite materials in the shape of the main plank member. The top cap has an extruded plastic construction formed with downwardly directed sidewalls to wrap around and releaseably interlock with the main plank member.
The main plank member has a construction of composite materials including a binder used to hold the composite materials in the shape of the main plank member. The top cap has an extruded plastic construction formed with downwardly directed sidewalls to wrap around and releaseably interlock with the main plank member.
Description
DECK BOARD WITH COMPOSITE BASE AND PYC COYER
FIELD OF THE INVENTION
The present invention relates to a deck board or plank made of a combination of plastic and composite materials.
BACKGROUND OF THE INVENTION
Conventional wooden deck boards are often being replaced with plastic deck boards. These new plastic deck boards have the benefit that they are extremely long lasting with essentially no maintenance requirement.
Most of the relatively recently available plastic deck boards have a one piece construction. There are however plastic deck boards available with a two piece construction. In the known two piece construction plastic deck board a plastic top piece interlocks with a plastic support piece beneath the top piece. The support piece typically has a substantially hollow construction which saves on the amount of material used to make the support piece. The hollow construction includes upstanding ribs which sit directly beneath and supports the top piece of the plank or deck member. The top piece itself has a relatively thick or heavy construction in that it is a load bearing surface sitting directly atop the ribs of the support piece.
The plastic deck boards which are currently on the market, although having substantial benefits over conventional wooden deck boards, are still relatively expensive because of the expense of the materials used in constructing them.
FIELD OF THE INVENTION
The present invention relates to a deck board or plank made of a combination of plastic and composite materials.
BACKGROUND OF THE INVENTION
Conventional wooden deck boards are often being replaced with plastic deck boards. These new plastic deck boards have the benefit that they are extremely long lasting with essentially no maintenance requirement.
Most of the relatively recently available plastic deck boards have a one piece construction. There are however plastic deck boards available with a two piece construction. In the known two piece construction plastic deck board a plastic top piece interlocks with a plastic support piece beneath the top piece. The support piece typically has a substantially hollow construction which saves on the amount of material used to make the support piece. The hollow construction includes upstanding ribs which sit directly beneath and supports the top piece of the plank or deck member. The top piece itself has a relatively thick or heavy construction in that it is a load bearing surface sitting directly atop the ribs of the support piece.
The plastic deck boards which are currently on the market, although having substantial benefits over conventional wooden deck boards, are still relatively expensive because of the expense of the materials used in constructing them.
SUN~ARY OF THE PRESENT INVENTION
The present invention relates to a deck board or plank having the high durability, low maintenance qualities of a full plastic deck board without having the high costs associated with the known plastic deck boards.
More specifically, the present invention relates to a deck board or plank comprising a main plank member and a top cap which removeably secures to the main plank member. The main plank member has a construction of composite materials and includes a resin binder used to hold the composite materials in the shape of the main plank member.
The top cap has a plastic construction formed, preferably in an extrusion process, with downwardly directed outer edge walls which wrap around and releaseably interlock with the main plank member.
The main plank member with its composite construction does not need to have a plastic construction in that other materials such as waste materials can be used in forming the main plank member. Furthermore, even if plastic materials are used in the composite construction of the main plank member they do not need to be virgin materials but rather can be recycled materials.
The reason these types of materials can be used is that the main plank member is covered from above by the top cap which is preferably made from virgin plastic materials. Accordingly, the overall deck plank maintains a high quality appearance without using expensive materials in the main plank member which constitutes most of the deck plank.
The present invention relates to a deck board or plank having the high durability, low maintenance qualities of a full plastic deck board without having the high costs associated with the known plastic deck boards.
More specifically, the present invention relates to a deck board or plank comprising a main plank member and a top cap which removeably secures to the main plank member. The main plank member has a construction of composite materials and includes a resin binder used to hold the composite materials in the shape of the main plank member.
The top cap has a plastic construction formed, preferably in an extrusion process, with downwardly directed outer edge walls which wrap around and releaseably interlock with the main plank member.
The main plank member with its composite construction does not need to have a plastic construction in that other materials such as waste materials can be used in forming the main plank member. Furthermore, even if plastic materials are used in the composite construction of the main plank member they do not need to be virgin materials but rather can be recycled materials.
The reason these types of materials can be used is that the main plank member is covered from above by the top cap which is preferably made from virgin plastic materials. Accordingly, the overall deck plank maintains a high quality appearance without using expensive materials in the main plank member which constitutes most of the deck plank.
BRIEF DESCRIPTTON OF THE DRAWINGS
The above as well as other advantages and features of the present invention will be described in greater detail according to the preferred embodiments of the present invention in which;
Figure 1 shows a deck construction using deck planks made in accordance with a preferred embodiment of the present invention;
Figure 2 is a top perspective view of the main plank member of an individual one of the deck planks from the deck construction of Figure 1;
Figure 3 is a bottom perspective view of the main plank member of the deck plank of Figure 2;
Figure 4 is a perspective view looking down on the main plank member of Figure 3 as it is being installed on a support surface for the deck plank;
Figure 5 shows further assembly of the deck plank of Figure 4;
Figure 6 is an end view showing assembly of the deck planks from the construction of Figure 1;
Figure 7 shows a capping member for capping the end of the deck planks of the construction of Figure 1;
Figure 8 is a perspective view of a further deck construction; and Figure 9 shows a connecting assembly of end to end deck planks from the deck construction of Figure 8.
The above as well as other advantages and features of the present invention will be described in greater detail according to the preferred embodiments of the present invention in which;
Figure 1 shows a deck construction using deck planks made in accordance with a preferred embodiment of the present invention;
Figure 2 is a top perspective view of the main plank member of an individual one of the deck planks from the deck construction of Figure 1;
Figure 3 is a bottom perspective view of the main plank member of the deck plank of Figure 2;
Figure 4 is a perspective view looking down on the main plank member of Figure 3 as it is being installed on a support surface for the deck plank;
Figure 5 shows further assembly of the deck plank of Figure 4;
Figure 6 is an end view showing assembly of the deck planks from the construction of Figure 1;
Figure 7 shows a capping member for capping the end of the deck planks of the construction of Figure 1;
Figure 8 is a perspective view of a further deck construction; and Figure 9 shows a connecting assembly of end to end deck planks from the deck construction of Figure 8.
DETAILED DESCRIPTION ACCORDTNG TO THE PREFERRED
EMBODIMENTS OF THE PRESENT INVENTION IN WHICH:
Figure 1 shows a deck construction generally indicated at 1 having an upper deck surface 5. This deck surface is formed by deck planks 7 supported by joists 3.
By looking at for example, Figures 2 and 7 of the drawings it will be seen that each of the deck planks 7 is formed by a main plank member generally indicated at 9 20 and covered by a top cap 11. Cap 11 has a construction made of a virgin plastic material. The cap which is essentially the only part of the deck plank which can be seen when the plank is in use has an esthetically appealing appearance.
A typical plastic used in the formation of the top cap 11 is PVC which according to a preferred embodiment of the present invention is extruded in a continuous length to the shape shown in the drawings. The continuous length of extruded cap is then cut to a specific desired length to match that of the main or support member 9 of the plank.
Member 9 has a composite material construction.
This member which is preferably formed in an injection molding process can be made from many different types of composite materials which are typically waste materials put to good use in this particular application. These materials are then held in the shape of the main plank member by a binder used in the injection molding process.
The actual construction of plank member 9 can best be seen having reference to Figures 3 and 6 of the drawings. Unlike typical plastic plank members, plank member 9 is formed with a solid top wall 13 which, as can been seen in Figure 6 of the drawings, is substantially thicker than cap 11. This solid top wall is bordered by sidewalls 19 and endwalls 21 to the opposite sides and opposite ends of plank member 9. The side and end walls border a generally hollow undersurface 25 of the plank member. This undersurface includes a first set of ribs 27 and 29 and a second set of ribs 31 and 33 which run lengthwise for the full length of the plank member.
Cross ribs 35 extend across the plank member with diagonal ribs 36 extending between the cross ribs 35.
The diagonal ribs which add substantially to the strength of the main plank member and which are particularly useful in controlling warpage, expansion and contraction of the plank member cannot be formed in an extrusion process because of their angled direction on the undersurface of the plank member. This shaping of the diagonal strengthening ribs is however possible in an injection or even a compression molding operation.
An important feature of the invention should be noted. As seen in Figure 9 the top wall 13 of the plank member 9 not only forms a substantially continuous surface, other than at grooves 17 to be described later in detail, but is additionally quite a thick surface.
This thick top surface, which like the rest of the main plank member, is made from very inexpensive materials, allows the use of a much thinner top cap made of more expensive covering material. It is top surface 31 of the main plank member which is the load bearing surface of the deck plank. The thinner top cap is merely a decorative cover over the main plank member.
Figures 3 and 6 of the drawings also show that main plank member 9 includes outer edge protrusions 15 over the sidewalls 19 of the main plank member. These outer edge protrusions include an upwardly opening groove 16 which is used to receive the downwardly directed sidewall 12 of top cap 11. Sidewall 12 has a hook shape to releasably snap lock into the groove 16 of protrusion 15 on the main plank member. Top cap 11 is replaceable on plank 9 with other top caps of various different colors to change the appearance of the deck without having to replace the main planks. This is particularly beneficial in that the more expensive virgin material used to make the external visible cap only constitutes about 5 to 10 percent of the overall deck. As such changing the appearance of the deck by changing the top cap is a relatively inexpensive venture.
Figure 6 of the drawings shows that the plank member has a slight downwardly angled shoulder 18 at the outer edge at its top wall 13 while the top cap is completely flat across its top surface. This leaves a slight gap 20 between the top cap 11 and the shoulder 18.
This gap 20 provides room for flexing of the top cap to snap its sidewall 12 over protrusion 15 of the main plank member.
Continuing to refer to Figures 3 and 6 it will be seen that the main plank member 9 includes the earlier described grooves 17 spaced from one another in the top surface 13 of the plank member. Figure 2 of the drawings shows that these grooves 17 run the full length of plank member 9. The continuous nature of grooves 17 which provide screw ports for mounting the deck planks to the joists is a very beneficial feature of the invention.
More particularly, the continuous screw ports i.e., grooves 17 which receive mounting screws as shown in Figure 6 of the drawings eliminates the requirement to have to locate the joists at specific locations beneath the deck boards. In other words, the deck boards will always be located beneath part of the screw port. The only thing that requires alignment with the joists are _ 7 _ the actual mounting screws.
Each of the grooves 17 is in the form of a T
shaped slot. This slot has an enlarged upper slot part 37 which narrows to a smaller slot part 41. Slot part 41 extends to a slot base 43 formed of solid material which is located directly over a further slot bordered by lower ribs 27 and 29 beneath one of the grooves and lower ribs 33 and 31 beneath the other of the grooves.
As seen in the fully assembled deck boards to the right hand side of Figure 6 the mounting screw once fully installed sits in a position where the head of the screw locates within the larger slot part 37 of the groove beneath the upper surface of the top cap 13 of the plank member. The screw therefore does not interfere with the flat fitting of top cap 11 to the main plank member.
The main threaded body of the mounting screw 20, threads downwardly through the slot bottom 43 and is tightly engaged by the two ribs on the undersurface of the main plank member. The screw then bites into the joist as seen in Figure 6.
With the above assembly the deck plank is not only held to the joist but additionally is positively engaged by the mounting screw over much of the length of the screw adding to the overall stability of the mounting of the deck board to the joist.
Figures 2 and 4 of the drawings show another feature of the invention in which the main member 9 of the deck plank is provided along one of its sidewalls with spacer tabs 23. Note that these spacer tabs are one side only of plank member 9.
_ g _ The plank member is provided with cut outs 24 directly above the spacer tabs 23. These cut outs enable an easy removal of the main plank member from the injection mold in which plank member 9 is preferably formed.
Figure 6 of the drawings shows how the spacer tabs 23 provide an accurate properly aligned mounting of side by side deck planks in the deck construction. In this alignment there is still a gap G provided between the individual deck planks. This gap leaves space for the snap locking of the top covers to the main deck members after they have been secured to the joist. The gaps also provide an area for water drainage down through the mounted deck boards.
Also to be noted is the actual construction of the space tabs. They are relatively tall so that each tab has an elongated contact with an adjacent board. This helps to prevent any toppling effect between boards.
Furthermore, each tab 23 is supported by reinforcing tab wings 23a to each side of each tab. These wings essentially preclude breakage of the tab from the side of the deck board.
Figure 7 of the drawings shows a further embodiment of the invention in which the deck is completed with an end cap 51 which slides over the ends of the mounted deck boards. This end cap which is preferably made form the same material as the top caps of the boards can be held in place by suitable adhesives.
It gives the end of the deck a very finished appearance by not only covering the ends of the boards but by additionally providing a continuous finish along the end of the deck. Similar caps may be placed along the side edges of the deck if desired.
Figure 8 of the drawings shows another embodiment of the invention used in forming a larger decking surface than what is shown in Figure 1. Typically the main plank members of each of the deck planks will have a maximum length of about 12 feet which even at this length necessitates an extremely large injection mold. In order to avoid the requirement for even a larger mold to make longer deck planks two or more deck planks can be mounted end to end with one another in forming multiple deck surfaces as shown in Figure 8. However in order to give these multiple deck surfaces a unitary appearance a joining member generally indicated at 53 is used to mate the ends of aligned deck boards. This joining member like cap 51 again is preferably made from the same material as used in the top caps of the deck boards. It has an I-beam shape to receive the deck board ends to each side of the cap member 53 producing the finished continuous deck appearance of Figure 8.
Although various preferred embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that variations may be made without departing from the spirit of the invention or the scope of the appended claims.
EMBODIMENTS OF THE PRESENT INVENTION IN WHICH:
Figure 1 shows a deck construction generally indicated at 1 having an upper deck surface 5. This deck surface is formed by deck planks 7 supported by joists 3.
By looking at for example, Figures 2 and 7 of the drawings it will be seen that each of the deck planks 7 is formed by a main plank member generally indicated at 9 20 and covered by a top cap 11. Cap 11 has a construction made of a virgin plastic material. The cap which is essentially the only part of the deck plank which can be seen when the plank is in use has an esthetically appealing appearance.
A typical plastic used in the formation of the top cap 11 is PVC which according to a preferred embodiment of the present invention is extruded in a continuous length to the shape shown in the drawings. The continuous length of extruded cap is then cut to a specific desired length to match that of the main or support member 9 of the plank.
Member 9 has a composite material construction.
This member which is preferably formed in an injection molding process can be made from many different types of composite materials which are typically waste materials put to good use in this particular application. These materials are then held in the shape of the main plank member by a binder used in the injection molding process.
The actual construction of plank member 9 can best be seen having reference to Figures 3 and 6 of the drawings. Unlike typical plastic plank members, plank member 9 is formed with a solid top wall 13 which, as can been seen in Figure 6 of the drawings, is substantially thicker than cap 11. This solid top wall is bordered by sidewalls 19 and endwalls 21 to the opposite sides and opposite ends of plank member 9. The side and end walls border a generally hollow undersurface 25 of the plank member. This undersurface includes a first set of ribs 27 and 29 and a second set of ribs 31 and 33 which run lengthwise for the full length of the plank member.
Cross ribs 35 extend across the plank member with diagonal ribs 36 extending between the cross ribs 35.
The diagonal ribs which add substantially to the strength of the main plank member and which are particularly useful in controlling warpage, expansion and contraction of the plank member cannot be formed in an extrusion process because of their angled direction on the undersurface of the plank member. This shaping of the diagonal strengthening ribs is however possible in an injection or even a compression molding operation.
An important feature of the invention should be noted. As seen in Figure 9 the top wall 13 of the plank member 9 not only forms a substantially continuous surface, other than at grooves 17 to be described later in detail, but is additionally quite a thick surface.
This thick top surface, which like the rest of the main plank member, is made from very inexpensive materials, allows the use of a much thinner top cap made of more expensive covering material. It is top surface 31 of the main plank member which is the load bearing surface of the deck plank. The thinner top cap is merely a decorative cover over the main plank member.
Figures 3 and 6 of the drawings also show that main plank member 9 includes outer edge protrusions 15 over the sidewalls 19 of the main plank member. These outer edge protrusions include an upwardly opening groove 16 which is used to receive the downwardly directed sidewall 12 of top cap 11. Sidewall 12 has a hook shape to releasably snap lock into the groove 16 of protrusion 15 on the main plank member. Top cap 11 is replaceable on plank 9 with other top caps of various different colors to change the appearance of the deck without having to replace the main planks. This is particularly beneficial in that the more expensive virgin material used to make the external visible cap only constitutes about 5 to 10 percent of the overall deck. As such changing the appearance of the deck by changing the top cap is a relatively inexpensive venture.
Figure 6 of the drawings shows that the plank member has a slight downwardly angled shoulder 18 at the outer edge at its top wall 13 while the top cap is completely flat across its top surface. This leaves a slight gap 20 between the top cap 11 and the shoulder 18.
This gap 20 provides room for flexing of the top cap to snap its sidewall 12 over protrusion 15 of the main plank member.
Continuing to refer to Figures 3 and 6 it will be seen that the main plank member 9 includes the earlier described grooves 17 spaced from one another in the top surface 13 of the plank member. Figure 2 of the drawings shows that these grooves 17 run the full length of plank member 9. The continuous nature of grooves 17 which provide screw ports for mounting the deck planks to the joists is a very beneficial feature of the invention.
More particularly, the continuous screw ports i.e., grooves 17 which receive mounting screws as shown in Figure 6 of the drawings eliminates the requirement to have to locate the joists at specific locations beneath the deck boards. In other words, the deck boards will always be located beneath part of the screw port. The only thing that requires alignment with the joists are _ 7 _ the actual mounting screws.
Each of the grooves 17 is in the form of a T
shaped slot. This slot has an enlarged upper slot part 37 which narrows to a smaller slot part 41. Slot part 41 extends to a slot base 43 formed of solid material which is located directly over a further slot bordered by lower ribs 27 and 29 beneath one of the grooves and lower ribs 33 and 31 beneath the other of the grooves.
As seen in the fully assembled deck boards to the right hand side of Figure 6 the mounting screw once fully installed sits in a position where the head of the screw locates within the larger slot part 37 of the groove beneath the upper surface of the top cap 13 of the plank member. The screw therefore does not interfere with the flat fitting of top cap 11 to the main plank member.
The main threaded body of the mounting screw 20, threads downwardly through the slot bottom 43 and is tightly engaged by the two ribs on the undersurface of the main plank member. The screw then bites into the joist as seen in Figure 6.
With the above assembly the deck plank is not only held to the joist but additionally is positively engaged by the mounting screw over much of the length of the screw adding to the overall stability of the mounting of the deck board to the joist.
Figures 2 and 4 of the drawings show another feature of the invention in which the main member 9 of the deck plank is provided along one of its sidewalls with spacer tabs 23. Note that these spacer tabs are one side only of plank member 9.
_ g _ The plank member is provided with cut outs 24 directly above the spacer tabs 23. These cut outs enable an easy removal of the main plank member from the injection mold in which plank member 9 is preferably formed.
Figure 6 of the drawings shows how the spacer tabs 23 provide an accurate properly aligned mounting of side by side deck planks in the deck construction. In this alignment there is still a gap G provided between the individual deck planks. This gap leaves space for the snap locking of the top covers to the main deck members after they have been secured to the joist. The gaps also provide an area for water drainage down through the mounted deck boards.
Also to be noted is the actual construction of the space tabs. They are relatively tall so that each tab has an elongated contact with an adjacent board. This helps to prevent any toppling effect between boards.
Furthermore, each tab 23 is supported by reinforcing tab wings 23a to each side of each tab. These wings essentially preclude breakage of the tab from the side of the deck board.
Figure 7 of the drawings shows a further embodiment of the invention in which the deck is completed with an end cap 51 which slides over the ends of the mounted deck boards. This end cap which is preferably made form the same material as the top caps of the boards can be held in place by suitable adhesives.
It gives the end of the deck a very finished appearance by not only covering the ends of the boards but by additionally providing a continuous finish along the end of the deck. Similar caps may be placed along the side edges of the deck if desired.
Figure 8 of the drawings shows another embodiment of the invention used in forming a larger decking surface than what is shown in Figure 1. Typically the main plank members of each of the deck planks will have a maximum length of about 12 feet which even at this length necessitates an extremely large injection mold. In order to avoid the requirement for even a larger mold to make longer deck planks two or more deck planks can be mounted end to end with one another in forming multiple deck surfaces as shown in Figure 8. However in order to give these multiple deck surfaces a unitary appearance a joining member generally indicated at 53 is used to mate the ends of aligned deck boards. This joining member like cap 51 again is preferably made from the same material as used in the top caps of the deck boards. It has an I-beam shape to receive the deck board ends to each side of the cap member 53 producing the finished continuous deck appearance of Figure 8.
Although various preferred embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that variations may be made without departing from the spirit of the invention or the scope of the appended claims.
Claims (11)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A deck plank comprising a main plank member and a top cap which removably secures to said main plank member, said main plank member having a construction of composite materials including a binder used to hold said composite materials in a shape of said main plank member, said top cap having an extruded plastic construction formed with downwardly directed sidewalls to wrap around and interlock with said main plank member, said top cap being releasable from and replaceable on said main plank with other top caps of various different colors.
2. A deck plank as claimed in Claim 1 wherein said main plank member is injection molded.
3. A deck plank as claimed in Claim 2 wherein said main plank member includes a solid top surface with first and second spaced apart grooves in said top surface extending lengthwise of and providing continuous screw ports in said main plank member.
4. A deck plank as claimed in Claim 3 wherein said solid top surface of said main plank member has a thicker construction than said top cap.
5. A deck plank as claimed in Claim 4 wherein each of said grooves comprises a T shaped slot which is removably covered by said top cap.
6. A deck plank as claimed in Claim 5 having hollow regions which occupy a major portion of said main plank member beneath said top surface, some of said hollow regions including transverse ribs extending across said main plank member and diagonal cross ribs intersecting with said cross ribs.
7. A deck plank as claimed in Claim 5 wherein said main plank member includes sidewalls and endwalls extending downwardly from said top surface and bordering a main hollow undersurface of said main plank member beneath said top surface thereof.
8. A deck plank as claimed in Claim 7 wherein said main hollow undersurface includes a first pair of spaced apart ribs and a second pair of spaced apart ribs extending lengthwise of said main plank member, said first pair of spaced apart ribs being located directly beneath said first channel and said second pair of spaced apart ribs being located directly beneath said second channel in said top surface of said main plank member.
9. A deck plank as claimed in Claim 7 including spacer tabs projecting laterally from one of said sidewalk of said main plank member.
10. A deck board as claimed in Claim 9 wherein each of said tabs is elongated vertically of the deck plank and includes reinforcing support wings to each side of each tab.
11. A deck plank as claimed in Claim 9 wherein said main plank member includes outer edge protrusions running lengthwise of said main plank member to both sides thereof, said protrusions extending outwardly beyond said sidewalls of said main plank member and having downwardly opening grooves therein for receiving upwardly directed lips of said sidewalls of said top cap, said top cap being flexible for snap lacking said sidewalls of said top cap onto said outer edge protrusions of said main plank member, said spacer tabs being located below and protruding latterly beyond the outer edge protrusions on the one of said sidewalk of said main plank member.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002488528A CA2488528A1 (en) | 2004-11-25 | 2004-11-25 | Deck board with composite base and pvc cover |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002488528A CA2488528A1 (en) | 2004-11-25 | 2004-11-25 | Deck board with composite base and pvc cover |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2488528A1 true CA2488528A1 (en) | 2006-05-25 |
Family
ID=36481096
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002488528A Abandoned CA2488528A1 (en) | 2004-11-25 | 2004-11-25 | Deck board with composite base and pvc cover |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2488528A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11060304B1 (en) | 2020-03-27 | 2021-07-13 | Strongwell Corporation | Deck board apparatus and method of making same |
-
2004
- 2004-11-25 CA CA002488528A patent/CA2488528A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11060304B1 (en) | 2020-03-27 | 2021-07-13 | Strongwell Corporation | Deck board apparatus and method of making same |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued | ||
| FZDE | Discontinued |
Effective date: 20101125 |